Optical element having an integral surface diffuser

ABSTRACT

A monolithic element has a substrate body and at least one macro-optical characteristic integral in a first portion of the optical element. A plurality of surface micro-structures are integral in a portion of the optical element. The micro-structures are designed to homogenize light passing through the optical element to produce a predetermined pattern of smoothly varying, non-discontinuous light exiting the optical element. The light exiting the optical element is therefore altered according to both the macro-optical characteristic of the optical element as well as the homogenizing characteristics of the micro-structures.

The present application is a divisional application of U.S. patentapplication Ser. No. 09/139,488, filed Aug. 25, 1998, now patented withU.S. Pat. No. 6,266,476.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to the field of optics, and moreparticularly to various optical elements incorporating an integralsurface diffuser as a portion of the optical element.

2. Description of the Related Art

There are many types of optical elements useful for an endless number ofcurrent and new applications. These optical elements are placed in abeam or path of light to change the characteristics of the light passingthrough the optical elements. Such optical elements may be as simple asa conventional cylindrical lens where a beam of light entering the lensremains unaffected in its width and is spread by the cylindrical lenscontour in a direction perpendicular to its width. An example of anotheroptical element is a transparent medium having a flat surface on oneside and a concave or convex surface on the other side which changes thecharacteristics of light passing through the lens. Such lenses arecommonly used for eyeglasses, magnifying glasses, film projectors andsimilar objects.

Other types of optical elements are known and may include Fresnelstructures, grating structures, filters, Total internal reflection (TIR)structures, nonlinear optical elements such as GRIN lenses, prismaticstructures, polarizers, pillow optic formations, fiber optic cables andother types of optical wave guides. All of these structures receive alight input from a light source and transmit or reflect the lightthrough the structure or element and then permit the light to exit fromthe structure or element in a somewhat altered state. All of these typesof optical elements either transmit, reflect, diffract, refract, orfilter out certain wavelengths of the light as it exits the structure orelement.

Each of these optical elements receives light from a light source havingparticular characteristics defined by the properties of the light sourceand then alter the light propagating through the optical element.However, none of these optical elements is capable of improving theoptical qualities of the light in a manner which evens or smoothes outthe light by eliminating high-intensity spots and low-intensity spotswithin the source. By evenly diffusing the light traveling in or throughthe optical element the output is made smooth and non-discontinuous.Additionally, none of these types of optical elements is capable ofsubstantially reducing or eliminating scatter of light and directingsubstantially all or most of the light photons in a particular desireddirection, pattern, or envelope. Virtually all of these known opticalelements merely perform a particular optical function as light passesthrough or reflects off of the element.

For example, a fiber optic cable is designed to take in light energy atone end and via the predetermined refractive index of the fibermaterials (core and cladding) continually and internally reflects thelight as it passes through the fiber so that essentially all the lightexits the fiber optic cable in substantially the same form in which itwas received (ignoring modal variations). Convex lenses used in suchobjects as eyeglasses and projector lenses (which use multiple lenses)slightly bend the light as it enters one side of the lens according tothe amount of curvature or shape of the lens or lenses and the materialsutilized to manufacture the lens. A Fresnel lens includes a plurality ofFresnel structures provided on a surface of the lens which bend orrefract the light in order to collimate or focus light passing throughthe lens. Many other optical elements are available which perform aparticular optical function on light. These optical elements are notcapable of smoothing out or “homogenizing” the light intensityvariations exiting the optical element or directing substantially all ofthe light in a particular direction and in a particular shape, envelope,or pattern. Consequently, in prior art optical elements, a significantamount of light is lost or wasted.

Diffusers have been applied as a separate layer to optical elements inorder to add both light diffusing and directing characteristics. In sucha construction, a laminate is formed including a sheet or a layer ofdiffuser material applied or adhered to a surface of an optical element,such as for example, a Fresnel lens. One problem with such aconstruction is that the sheet material is not very durable and iseasily damaged, scratched or otherwise deformed during use. Anotherproblem is that the diffuser sheet metal may simply peel away from theoptical element over time or under certain conditions. Another even morecritical problem with such a laminate construction is that the matingsurfaces between the two portions of the laminate create an interfacewhich refracts or reflects a portion of light entering the opticalelement. This Fresnel reflection causes a minimum loss of 4% of theincident light at each mating surface which therefore does not passthrough the diffuser and optical element or is otherwise altered in anundesirable manner. A further problem with such a construction is thatan index matching optical grade epoxy or adhesive must be used in orderto adhere the two parts of the laminate together. The optical gradeepoxy permits passage of light through itself but creates an additionallayer or refractive surface at each contact point, and hence additionalFresnel losses, both between the diffuser layer and the epoxy andbetween the optical element and the epoxy. The epoxy layer also addscost to the laminate construction as well as manufacturing complexity.Another problem with the epoxy is that there may be instances where theepoxy is not in complete contact with one surface of the laminate or hasair bubbles between the epoxy and one of the laminate layers or withinthe epoxy itself. Such irregularities cause further problems (i.e.,scattering) with light passing within the laminate optical element. Allthe above problems greatly reduce the performance and desirability oflaminated optical elements.

The assignee of the present invention has invented several ways offorming a plurality of surface micro-structures in various materials toform a surface diffuser on such materials. These methods are describedin a number of issued patents and co-pending patent applications listedbelow. Many of these methods involve creating a master diffuser byexposing a photoresist material to a source of light and thenreplicating this master diffuser into one or more submasters of a moredurable nature. There are also other methods of making replicas of amaster diffuser which contain the optical features in the master. Withsome of these methods, the master diffuser is initially createdoptically. With others, it is created mechanically. Submasters arecreated from these master diffusers utilizing a number of methodswhereby the master diffuser surface is replicated into a submastersurface. These other methods are described in one or more pending U.S.applications, referenced below, which are assigned to the assignee ofthe present invention.

Other commonly assigned U.S. patents and pending applications discloserelated methods for making and recording optical products andreplicating those products so that they may be mass produced. Forexample, U.S. Pat. No. 5,365,354 entitled “Grin Type Diffuser Based onVolume Holographic Material,” U.S. Pat. No. 5,534,386 entitled“Homogenizer Formed Using Coherent Light and a Holographic Diffuser,”and U.S. Pat. No. 5,609,939 entitled “Viewing Screen Formed UsingCoherent Light,” all owned by the present assignee relate to methods forrecording and replicating optical products. Each of these U.S. patentsis incorporated herein by reference for purposes including, but notlimited to, indicating the background of the present invention andillustrating the state of the art.

Related U.S. patent applications include Ser. No. 08/782,962 entitled“Apparatus for LCD Backlighting,” now U.S. Pat. No. 6,072,551, Ser. No.09/052,586 entitled “Method of Making Replicas While Preserving Master,”now U.S. Pat. No. 6,159,398, Ser. No. 08/595,307 entitled “LCD WithLight Source Destructuring and Shaping Device,” now U.S. Pat. No.5,956,106 Ser. No. 08/601,133 entitled “Liquid Crystal Display Systemwith Collimated Backlighting and Non-Lambertian Diffusing,” now U.S.Pat. No. 5,838,403, Ser. No. 08/618,539 entitled “Method of MakingLiquid Crystal Display System,” now U.S. Pat. No. 5,735,988, Ser. No.08/800,872 entitled “Method of Making Replicas and Compositions for UseTherewith,” now U.S. Pat. No. 5,922,238, and Ser. No. 09/075,023entitled “Method and Apparatus for Making Optical Masters UsingIncoherent Light,” “Non-Lambertian Glass Diffuser and Method of Making,”filed Aug. 20, 1998, “Diffuser Master and Method of Manufacture,” filedAug. 20, 1998, “High Efficiency Monolithic Glass Light Shaping Diffuserand Method of Making,” filed Aug. 25, 1998, “Vehicle Light AssemblyIncluding a Diffuser Surface Structure,” filed Aug. 25, 1998, “ApparatusHaving a Light Source and a Sol-Gel Monolithic Diffuser,” filed Aug. 25,1998, “Passive Matrix Liquid Crystal Display,” filed Aug. 25, 1998, and“Device Including an Optical Element With a Diffuser,” filed Aug. 25,1998. All the above applications are owned by the present assignee andare hereby incorporated by reference for purposes including, but notlimited to, indicating the background of the present invention andillustrating the state of the art.

SUMMARY OF THE INVENTION

A monolithic optical element constructed in accordance with the presentinvention has a substrate body with at least one macro-opticalcharacteristic integral in a first portion of the optical element. Themonolithic optical element also includes a plurality of surfacemicro-structures integral in a portion of the optical element whereinthe micro-structures homogenize light passing through the opticalelement to produce a predetermined pattern of smoothly varying,non-discontinuous light which exits the optical element.

It is an object of the present invention to provide an optical elementwhich both has at least one macro-optical characteristic as well as alight diffusing and shaping surface structure provided by the surfacemicro-surface structures integral in a portion of the optical element.It is a further object of the present invention to provide such amonolithic optical element which is formed of one single body ofmaterial and is not a laminate construction. It is a further object ofthe present invention to provide a monolithic optical element whicheliminates the lossy reflective abutting surface between two componentsof a laminate which would otherwise create unwanted Fresnel reflectionlosses of 4% at each surface, and thus which substantially increasestransmission efficiency over the prior art. It is a still further objectof the present invention to provide a monolithic optical element whereinthe surface micro-structures of the diffuser surface are formed integralfrom the same material as the remainder of the optical element toprovide a more durable and substantially more useful element and onewhich is less expensive to manufacture.

In one embodiment, the substrate body of the optical element is aFresnel lens wherein the at least one macro-optical characteristic is aplurality of Fresnel optics. In another embodiment, the substrate bodyis an elongate fiber optic cable or optical waveguide and the at leastone macro-optical characteristic is a refractive index or indices of thecable. In other embodiments of the invention, the monolithic opticalelement is any type of optical lens such as a concave or convex lens, anaspheric lens, a polarizer, a prismatic structure, a filter, a gratingstructure, or a total internal reflection lens wedge (“light pipe”), orretroreflector. In yet another embodiment the monolithic optical elementis a lightpipe such as for use in a laptop computer display. In any ofthese embodiments, the particular lens characteristic or structure isformed integral as a portion of the substrate body and themicro-structures which provide the diffusing and light shapingcharacteristics are also formed integral in a portion of the substratebody. In one embodiment, the micro-structures are formed integral in aportion of the substrate body separate from the macro-opticalcharacteristic. In an alternative embodiment, the micro-structures areformed integral in the same surface of the optical element as themacro-optical characteristic.

These and other aspects and objects of the present invention will bebetter appreciated and understood when considered in conjunction withthe following description and accompanying drawings. It should beunderstood, however, that the following description, while indicatingpreferred embodiments of the present invention as given by way ofillustration and not of limitation. Many changes and modifications maybe made within the scope of the present invention without departing fromthe spirit thereof and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

A clear conception of the advantages and features of the presentinvention, and of the construction and operation of the typicalmechanisms provided with the present invention, will become more readilyapparent by referring to the exemplary and therefore nonlimitingembodiments illustrated in the drawings accompanying informing a part ofthis specification, and in which:

FIG. 1a illustrates an elevational perspective view of a Fresnel lensoptical element;

FIG. 1b illustrates a cross-sectional view taken along line 1 b—1 b ofthe Fresnel lens of FIG. 1a;

FIG. 2a illustrates an elevational perspective view of a cylindricallens optical element;

FIG. 2b illustrates a cross-sectional view of the cylindrical lens takenalong line 2 b—2 b of FIG. 2a;

FIGS. 2c and 2 d illustrate a cross-sectional view of alternativecylindrical lens optical elements;

FIG. 3a illustrates an elevational perspective view of a parabolicconvex lens optical elements;

FIG. 3b illustrates a cross-sectional view taken along line 3 b—3 b ofthe convex lens of FIG. 3a;

FIG. 4a illustrates an elevational perspective view of a fiber opticcable optical element;

FIG. 4b illustrates a cross-sectional view taken along line 4 b—4 b ofthe fiber optic cable of FIG. 4a;

FIG. 5a illustrates an elevational perspective view of a prismaticoptical element;

FIG. 5b illustrates a cross-sectional view taken along line 5 b—5 b ofthe prismatic optical element of FIG. 5a;

FIG. 6a illustrates an elevational perspective view of a polarizeroptical element;

FIG. 6b illustrates a cross-sectional view taken along line 6 b—6 b ofthe polarizer optical element of FIG. 6a;

FIG. 7a illustrates a wave guide filter grating optical element;

FIG. 7b illustrates a cross-sectional view of the wave guide filtergrating taken along line 7 b—7 b of FIG. 7a;

FIG. 8a illustrates an elevational perspective view of a parabolicconcave lens optical element;

FIG. 8b illustrates a cross-sectional view taken along line 8 b—8 b ofthe concave lens of FIG. 8a;

FIG. 9 illustrates a simple schematic view of total internal reflectionoptical element;

FIGS. 10a and 10 b illustrate a cross-sectional view of alternativeembodiments of an optical element of the invention; and

FIG. 11 illustrates a light pipe alternative embodiment according to theinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

According to the above listed patents and co-pending patent applicationsassigned to the assignee of the present invention, methods have beendeveloped by the assignee for optically or mechanically creatingmicro-sculpted surface structures or micro-structures in a substratewhich are random in nature and produce a light output with a smoothconsistent and continuous intensity. These micro-structures can also becreated in such a manner so as to control the direction of light outputfrom a light source so as to shape the light output into a desireddistribution pattern or envelope. The issued patents are directed toforming these surface structures by various means in photoresistmaterials and replicating theses structures in sub-masters. Thesesub-masters are utilized to further replicate the micro-structures insheets of material which may be laminated or otherwise applied toobjects in order to provide the light homogenizing, shaping anddirecting characteristics. The co-pending applications disclose thefurther developed techniques for novelly forming these micro-structuresin materials other than in epoxy and sheets of soft plastic.

The present invention is not to be limited to forming thesemicro-structures in any particular material and therefore the opticalelements described herein may be formed from such materials as sol-gelglass, quartz glass, polycarbonate and acrylic plastics, epoxies, andany other suitable plastic, glass or other moldable materials. Thepresent invention is directed to optical elements having integrallyformed micro-structures to produce a monolithic structure having boththe macro-optical characteristic associated with a particular opticalelement as well as the diffuser micro-structures to improve thecharacteristics of the light propagating therethrough, to minimizeunwanted Fresnel reflection losses and thereby actually increasetransmission efficiency, and to decrease cost of manufacture.

Referring now to the drawings, the figures illustrate a number ofpossible embodiments of particular optical elements which incorporatethe micro-structure integrally into the optical element to form amonolithic structure with improved and defined light propagationcharacteristics. The embodiments shown are not intended to exhaust thelist of possible optical elements but merely to illustrate some of thepossibilities. FIGS. 1a and 1 b illustrate an optical element in theform of a Fresnel lens 20. A Fresnel lens is typically utilized in manyapplications for taking light from a light source and spreading,collimating, or focusing the light according to the structuralcharacteristics of the Fresnel lens. For example, a Fresnel lens istypically utilized in many automotive applications for objects as simpleas interior dome lights, simple trailer lights and in various vehicletaillamp construction.

A Fresnel lens 20 constructed in accordance with the present inventionincludes a substrate body 22 which may be formed of any number ofmaterials but in many applications is molded from a plastic material.Additionally, the substrate body 22 may be formed in any number ofshapes, configurations and contours without departing from the scope ofthe present invention although the lens 20 is simply shown as a planarstructure. A conventional Fresnel lens 20 has on one surface thereof aplurality of Fresnel optics 24. These structures are typically in theform of a plurality of circular or oval shaped continuous ordiscontinuous ridges disposed radially outward from a center axisrelative to one another on the surface of the substrate body 22. Theparticular size, cross-sectional shape and contour of the Fresnel opticsas well as the size, curvature, and frequency of the continuous ringsdetermine the macro-optical characteristic of a particular Fresnel lens20. The Fresnel lens 20 constructed in accordance with the inventionhowever also includes a plurality of surface micro-structures 26 moldedinto the opposite side of the substrate body 22 according to one of theseveral methods disclosed in the above noted pending applications. Thesemicro-structures can be molded or embossed directly into this substratebody 22 during formation of the Fresnel lens 20 from a master substrate.The master substrate can be formed from a multi-step optical recordingprocess or form one of several novel mechanical means such as brushing,etching or shot blasting of the substrate as described in one or more ofthe above incorporated patents and patent applications. The result is amonolithic body 22 including both the macro-optical characteristicFresnel optics 24 on one surface and the micro-structures 26 on anothersurface of the body.

FIGS. 2a and 2 b illustrate an optical element in the form of acylindrical lens 30. The cylindrical lens 30 has a substrate body 32which on one side includes an elongate cylindrical surface 34 definingthe macro-optical characteristic of the lens. The opposite side of thesubstrate body 32 includes a plurality of the micro-structures 36 whichdefine the diffuser surface formed by the several methods disclosed inthe above noted co-pending United States patent and patent applications.FIGS. 2c and 2 d illustrate alternative embodiments of cylindrical lensstructures 37 and 41. FIG. 2c illustrates a substrate body 38 havingthereon a plurality of cylindrical lenses 40 on one side and a pluralityof the micro-structures 36 formed on the other side of the substrate 38.FIG. 2d illustrates an alternative substrate body 42 having thereon aplurality of inverted or reverse cylindrical lenses 44 formed thereon.The micro-structures 36 are formed on the opposite side of the substrate42.

In each of the embodiments of FIGS. 2a-2 d, the curvature and contour ofthe cylindrical lens surfaces 34, 40 and 44 define the macro-opticalcharacteristic of the lens 30 or alternative lenses 37 and 41. Themicro-structures 36 provide the novel diffusing characteristics and areagain molded or formed integral into a surface of the substrate bodies32, 38 and 42 along with the micro-optical characteristics for eachparticular embodiment. Therefore, each of the lenses 30, 37 or 41 areagain monolithic structures. Importantly, the monolithic nature of theoptical elements yields the highly desirable light diffusing and shapingadvantages without the attendant Fresnel losses in prior art laminatedstructures. In fact, the monolithic optical elements of the presentinvention actually and unexpectedly increase light transmission.

FIGS. 3a and 3 b illustrate an optical element in the form of aparabolic convex lens 50. The lens 50 includes a substrate body 52having on one side a curved or parabolic convex lens surface 54 and theplurality of micro-structures 56 formed on the opposite side of thesubstrate body 52. The parabolic convex lens surface 54 produces themacro-optical characteristic of the lens 50 and the micro-structures 56provide the diffusing characteristics according to the presentinvention. Again, transmission efficiency is actually increased overlaminated structures because the lens 50 is formed as a monolithicstructure wherein the parabolic convex surface 54 and themicro-structures 56 are formed integral as a part of the substrate bodymaterial.

Microstructures 56 may also be made nonuniform across the lens 50 tominimize certain lens aberrations. For example, as indicated by thearrows in FIG. 3 the microstructures 56 at the outer edges of the lensmay be designed to shape the light into a narrow distribution while themicrostructures 56 in the middle may provide a broader lightdistribution pattern.

FIGS. 4a and 4 b illustrate an optical element in the form of a fiberoptic cable 60 in an enlarged form. The cable 60 includes a longitudinalsubstrate body 62, a core 62 and an external cladding 64 surrounding thecore. The fiber optic element or cable 60 also has a distal end 66 atwhich the cable terminates. The refractive index of the fiber opticcable partially defines the macro-optical light propagatingcharacteristics of the cable.

In this embodiment, the plurality of micro-structures 68 are integrallyformed on the end 66 of the cable 60 during formation of the cable. Forexample, during conventional manufacturing of a fiber optic cable, thecable substrate 62 is formed in continuous lengths which are eventuallycut to size. Once cut, the end may already be heated or can then beheated after separation from the continuous cable whereby themicro-structures 68 are then molded, embossed, or otherwise replicatedin the end of the fiber optic cable 60. In this embodiment, the end ofthe fiber optic cable may be heated by any suitable means as long as thematerials of the core 62 and cladding 64 are elevated to a sufficienttemperature in order that the micro-structures 68 are replicated intothe material of the core 62. A monolithic structure is thus formedincluding the micro-structures 68 and the core 62.

FIGS. 5a and 5 b illustrate an optical element in the form of aprismatic structure 70. The structure 70 includes a substrate body 72and a plurality of prism structures 74 on one side. The prism structures74 may be in any configuration or construction including individualprismatic structures, a plurality of prism arrays, or merely a pluralityof elongate prism structures formed on the substrate 72. A plurality ofthe micro-structures 76 are formed on the opposite side of the substrate72. The substrate body 72, the macro-optical prism structures 74 and thediffuser micro-structures 76 are all formed integral in the monolithicprismatic structure 70.

FIGS. 6a and 6 b illustrate an optical element in the form of apolarizer 80 wherein the macro-optical characteristic is the filteringor polarizing property of the element and whereby the polarizers areembedded in a substrate body 82. The substrate body 82 has themicro-structures 84 on one surface of the substrate. The oppositesurface of the substrate is essentially flat in this embodiment becausethe polarizing capability of the substrate 82 is within the monolithicbody itself. The optical element in the form of a polarizer 80 hasformed in one surface a plurality of light diffusing or homogenizingmicro-structures which provide the enhanced transmission and diffusingcapabilities of the element.

FIGS. 7a and 7 b illustrate an optical element in the form of an opticalfilter grating structure 90. The grating structure 90 includes asubstrate body 92 and plurality of gratings 94 formed therein by one ofmany known means. The grating structures are spaced apart periodic linesformed in the substrate material 92 which filter out certain wavelengthsfrom the light source as it passes through or reflects off of thestructure 90. A plurality of the micro-structures 96 are formed into asurface of the grating structure 90 in the substrate body 92 duringmanufacture of the grating structure. The optical element is amonolithic construction wherein the macro-optical gratings 94 and themicro-structures 96 are integral in the material of the substrate body92.

FIGS. 8a and 8 b illustrate an optical element in the form of a concavelens 100. The concave lens 100 includes a substrate body 102 having aconcave surface 104 on one side and the plurality of micro-structures106 carried on the other side of the substrate. The curvature of thesurface 104 and the refractive index defines the macro-opticalcharacteristic of the lens 100 and the micro-structures 106 provide thediffusing or homogenizing characteristics of the lens 100. The curvedsurface 104 and the structures 106 are each integral into opposite sidesof the materials of the substrate body 102.

FIG. 9 illustrates a simple schematic view of another type of opticalelement in the form of a total internal reflection or TIR lens assembly110. The lens assembly 110 includes a TIR lens 112 which has on one sidea reflector surface 114 for reflecting light entering the lens 112 backtoward the direction from which it came at a predetermined angle. Inthis embodiment, the TIR lens 112 also includes a curved entrancesurface 116 which permits light to pass initially therethrough into thelens but then reflects light back toward the interior of the lens oncethe light is inside of the lens itself as illustrated in FIG. 9. Thecurvature of the surface 116 is determined by the angle of lightentering the lens 112 and the characteristics of the material from whichthe lens 112 is made as well as the reflector surface 114. A lightsource 118 is placed adjacent the lens 112 to direct light toward andinto the lens.

In the embodiment illustrated in FIG. 9, the light source is a standardfilament type incandescent light bulb which projects light in generallyall directions and therefore requires a back reflector 120 forreflecting some of the light back towards the lens 112 as illustrated inFIG. 9. The travel path of the light is indicated by the lines 122. Aportion of the lens 112 is intended to permit the light to exit from theinterior of the lens. In the present exemplary embodiment, light exitsthe opposed ends 124 of the lens 112. The microstructures 126 are formedon the surfaces 124 where the light exits the TIR lens 112 and is thusdiffused and directed according to the design characteristics of themicro-structures 126. Such a TIR lens may take on any number ofconfigurations and constructions and is utilized in many differentapplications. Thus, the exit surfaces of the lens may vary greatly fromthe simple schematic illustrated in FIG. 9. However, the diffusermicro-structures 126 are formed integral with the material of the TIRlens 112 on each intended exit surface as desired.

Such a TIR lens assembly 110 is found in many types of applications.These may include automotive lighting systems including taillightassemblies, global positioning systems(GPS) backlighting units,telephone display backlighting systems, pagers, watches, map lights,street lights, traffic signals, special effect and architecturallighting, light pipes, and many other applications where the lightsource is a LED, laser, a fiber or waveguide, or filament type lighting.In each of these applications it is critical to maximize light at byminimizing Fresnel and other reflection losses. By maximizingtransmission of light through the optical element in these devices,smaller sources may be used and enhanced device performance is realized.

FIGS. 10a and 10 b illustrate represent alternatives which are alsointended to be in the scope of the present invention. FIG. 10aillustrates a blown up view of a portion of the Fresnel optics 24illustrated for the Fresnel lens 20. Instead of the micro-structures 26being formed on an opposite side of the lens 20, the micro-structures 26may be formed directly on the surface of the Fresnel optics 24themselves as illustrated in FIG. 10a. Similarly FIG. 10b illustrates aportion of the concave parabolic lens 100 wherein the micro-structures106 are formed directly on the same surface that carries the curvedmacro-optical concave surface 104. It will be apparent by theseexemplary illustrations that in many of the above described embodiments,the micro-structures which form the homogenizing and/or light directingmicro-optical characteristics may be provided on the same surface whichcarries the macro-optical characteristics of the optical element. Insome applications, such a construction may not be possible because ofthe type of macro-optical characteristic such as, for example, the fiberoptic cable 60.

FIG. 11 represents another alternative within the scope of the presentinvention. FIG. 11 illustrates a lightpipe 130 having a CCFL lightsource 132. Lightpipe 130 has integral on the lower surface thereofgroove or facet structures 134 which may be TIR or partially mirrored.Integral in the top surface of lightpipe 130 are micro-structures 136which homogenize, shape, and direct light exiting the lightpipe 130toward the user such a lightpipe may be used in devices such as laptopcomputers or other electronic devices.

As described in many of the above referenced issued patents andco-pending patent applications, the micro-surface structures may beformed in the surface of many different materials which are capable ofbeing used for optical applications. Therefore, the present invention isnot to be limited to producing the main substrate body of any particularoptical element from a particular material. The optical elements maytake on any number of configurations and constructions, each having oneor more particular macro-optical characteristics. The materials fromwhich these optical elements are made thus may also vary considerably.

Though the invention has been described referring to particularembodiments, many other changes and modifications may be made to theinvention as described without departing from the spirit and scopethereof. The scope and spirit of these changes will become apparent fromthe appended claims. The scope of the invention is therefore intendedonly to be limited by the appended claims.

What is claimed is:
 1. A monolithic optical element through which lightis able to pass, comprising: a substrate body through which light isable to pass; a macro-optical characteristic integral with the substratebody; and a plurality of micro-structures through which light is able topass and which are random in nature and which are integral with thesubstrate body, wherein the micro-structures are characterized as beingable to homogenize light exiting the monolithic optical element via thesubstrate body, wherein the micro-structures are further characterizedas being able to direct a predetermined distribution of light exitingthe monolithic optical element via the substrate body in a manner so asto shape substantially all of a light output of the monolithic opticalelement into a predetermined direction and distribution pattern, whereinthe substrate body, the macro-optical characteristic integral therewithand the plurality of random micro-structures also integral therewithcooperate thereby to enable the monolithic optical element to producethe light output providing the predetermined direction and distributionpattern of smoothly varying, non-discontinuous light exiting themonolithic optical element, wherein the substrate body is a totalinternal reflection lens assembly and wherein the macro-opticalcharacteristic is a total internal reflection capability of the totalinternal reflection lens assembly, and wherein the total internalreflection lens assembly includes opposed end surface portions, theopposed end surface portions including the micro-structures from wherethe light within the total internal reflection lens assembly exits thetotal internal reflection lens assembly.
 2. The optical elementaccording to claim 1, wherein the substrate body is a plastic materialand wherein the macro-optical characteristic and the micro-structuresare each characterized as having been molded integral with the plasticmaterial.
 3. The optical element according to claim 1, wherein thesubstrate body is a hardened sol-gel solution and wherein themacro-optical characteristic and the micro-structures are eachcharacterized as having been formed integral with the hardened sol-gelsolution.
 4. The optical element according to claim 1, wherein thesubstrate body and the macro-optical characteristic integral therewithare of a glass material and wherein the microstructures arecharacterized as having been formed integral with the macro-opticalcharacteristic.
 5. A total internal reflection lens assembly throughwhich light is able to pass, comprising: a total internal reflectionlens having an entrance surface that is adapted to: (i) permit lightinitially to pass through said entrance surface into the lens, and (ii)reflect light away from the entrance surface as soon as the light isinside of the lens, wherein the total internal reflection lens iselongated and has opposite end surface portions from where the lightwithin the total internal reflection lens exits the lens; alight-reflective surface that is integral with the total internalreflection lens and that is spaced from and disposed toward the entrancesurface for reflecting the light entering the lens back toward theentrance surface at a predetermined angle; and a plurality ofmicro-structures through which light is able to pass and which arerandom in nature and which are integral with the opposite end surfaceportions of the total internal reflection lens, wherein themicro-structures are characterized as being not only able to homogenizelight exiting the total internal reflection lens via the opposite endsurface portions but also able to diffuse and shape the light, whereinthe micro-structures are further characterized as being able to direct apredetermined distribution of light exiting the total internalreflection lens via the opposite end surface portions in such a manneras to shape substantially all of a light output of the total internalreflection lens into a predetermined direction and distribution pattern,and wherein the entrance surface, the light-reflective surface, the lensend portions and the plurality of random micro-structures integraltherewith cooperate thereby to enable the total internal reflection lensto produce the light output having the predetermined direction anddistribution pattern of smoothly varying, non-discontinuous lightexiting the total internal reflection lens assembly.
 6. The totalinternal reflection lens assembly according to claim 5, furthercomprising a light source disposed adjacent the entrance surface fordirecting light toward and into the total internet reflection lens. 7.The total internal reflection lens assembly according to claim 5, hereinthe entrance surface is a curved entrance surface.
 8. The total internalreflection lens assembly according to claim 5, wherein the assembly issubstantially a plastic material and wherein the micro-structures arecharacterized as having been molded integral with the plastic material.9. The total internal reflection lens assembly according to claim 5,wherein the assembly is substantially a hardened sol-gel solution andwherein the micro-structures are each characterized as having beenformed integral with the hardened sol-gel solution.
 10. The totalinternal reflection lens assembly according to claim 5, wherein theassembly is substantially of a glass material and wherein themicro-structures are characterized as having been formed integral withthe macro-optical characteristic.
 11. A light pipe comprising: anelongated substrate body through which light is able to pass, whereinthe elongated substrate body has opposed longitudinal edge margins andopposite end portions, and wherein at least one of said opposite endportions is characterized as being able to receive light; a plurality oflight-reflective facet structures integral with a first of saidsubstrate body longitudinal edge margins; and a plurality ofmicro-structures which are random in nature and integral with a secondof said substrate body longitudinal edge margins, wherein themicro-structures are characterized as being not only able to homogenizelight exiting the second substrate body longitudinal end margin but alsoable to diffuse and shape the light, wherein the micro-structures arefurther characterized as being able to direct a predetermineddistribution of light exiting the second substrate body longitudinal endmargin in such a manner as to shape substantially all of a light outputof the elongated substrate body into a predetermined direction anddistribution pattern, wherein the light-reflective facet structures andthe plurality of random micro-structures cooperate thereby to enable theelongated substrate body to produce the light output providing thepredetermined direction and distribution pattern of smoothly varying,non-discontinuous light exiting the second substrate body longitudinalend margin; and wherein the random micro structures have a primary axisperpendicular to the mean propagation of light exiting the secondsubstrate body longitudinal end margin.
 12. The light pipe according toclaim 11, further comprising a light source in contact with the onesubstrate body end portion.
 13. The light pipe according to claim 11,wherein the substrate body is a plastic material and wherein thelight-reflective facet structures and the micro-structures are eachcharacterized as having been molded integral with the plastic material.14. The light pipe according to claim 11, wherein the substrate body isa hardened sol-gel solution and wherein the light-reflective facetstructures and the micro-structures are each characterized as havingbeen formed integral with the hardened sol-gel solution.
 15. The lightpipe according to claim 11, wherein the substrate body and thelight-reflective facet structures are of a glass material and whereinthe micro-structures are characterized as having been formed integralwith the macro-optical characteristic.